External mixing pressurized two-fluid nozzle and a spray drying method

ABSTRACT

Disclosed herein is an external mixing pressurized two-fluid nozzle for atomising a liquid by means of liquid pressure and gas, comprising an inner feed liquid pipe ( 1 ) extending axially between an upstream end and a downstream end, having a feed liquid conduit ( 2 ), a feed liquid inlet ( 3 ) positioned at the upstream end and a feed orifice ( 4 ) positioned at the downstream end, and a co-axial first gas pipe ( 5 ) extending radially outside the inner feed liquid pipe ( 1 ) and forming a first gas conduit ( 6 ) between the first gas pipe ( 5 ) and the inner feed liquid pipe ( 1 ), the first gas pipe ( 5 ) having a gas outlet slit ( 7 ) positioned at the downstream end. Said external mixing two-fluid nozzle provides a swirling motion of the gas, which combined with a pressurized feed liquid enables the production of spray dried powder at industrially applicable capacities with low energy consumption and a small particle size.

This application is a divisional of U.S. application Ser. No. 13/981,800filed Oct. 1, 2013, which is a National Stage of InternationalApplication No. PCT/DK2011/050060 filed Feb. 28, 2012, the contents ofall of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to an external mixing pressurizedtwo-fluid nozzle for atomising a liquid by means of a liquid pressureand a gas, comprising an inner feed liquid pipe extending axiallybetween an upstream end and a downstream end, having a feed liquidconduit, a feed liquid inlet positioned at the upstream end and a feedorifice positioned at the downstream end, and a co-axial first gas pipeextending radially outside the inner feed liquid pipe and forming afirst gas conduit between the first gas pipe and the inner feed liquidpipe, the first gas pipe having a gas outlet slit positioned at thedownstream end. The invention furthermore relates to a spray processingmethod for producing a spray dried powder by use of an external mixingpressurized two-fluid nozzle for producing droplets of a liquid by meansof a liquid pressure and a gas. In addition, the invention relates tothe use of said external mixing two-fluid nozzle for producing a spraydried powder.

BACKGROUND OF THE INVENTION

Spray drying is a drying process, which involves both particle formationand drying. It involves atomisation of a feed, typically a liquidconcentrate, into a spray and contact between the spray and a dryingmedium. The formation of the spray (atomisation) and the contacting ofthe spray with the drying medium may be achieved by use of a nozzle.

Pneumatic nozzle atomisation involves impacting a liquid feed with ahigh velocity gas. The high velocity gas creates high frictional forcesand disintegrates the liquid feed into spray droplets. The feed liquidis believed to break-up in two stages. The first phase involves thetearing of the liquid feed into filaments and large droplets. The secondphase completes the atomisation by breaking these liquid forms intosmaller and smaller droplets. The entire process is influenced by themagnitude of the surface tension, density, pressure and viscosity of theliquid feed as well as the velocity and density of the gaseous flow.

Various design techniques are available to produce the requiredconditions of liquid-gas contact for atomisation. As disclosed in thebook “Spray drying” by Keith Masters, 1991 edition, page 251, thedesigns may be divided into 4 categories:

-   (1) Internal mixing in which liquid feed and atomising gas are    contacted within the nozzle head.-   (2) External mixing, in which liquid feed and atomising gas are    contacting outside the nozzle head.-   (3) Combined internal and external mixing by using two atomising gas    flows within the nozzle head (three-fluid nozzle).-   (4) Pneumatic cup atomising, in which feed liquid and atomising gas    is contacted at the rim of a rotating nozzle head.

The different design techniques provide different properties and resultin different outcome of the final atomised product. In the first 2categories the feed liquid and atomising gas are passed separately tothe nozzle. Such nozzles, which are usually denoted two-fluid nozzles(TFN), are i.a. used for atomisation of a liquid in spray drying plantsand in fluid bed agglomeration. The liquids can be in the form ofsolutions, dispersion or pure substances. In particular, two-fluidnozzles are used when atomising a fluid, where fine droplets is theobjective or where additional atomisation energy in the form ofatomising gas is required to break up a fluid into droplets. Nozzledesigns of the third and fourth category are not the subject of thepresent application.

Internal mixing TFN has the advantage, compared to external mixing TFN,that it is mixing gas and liquid before the two fluids enter thesurrounding atmosphere of the drying chamber. However, nozzles providinginternal mixing are not as well suited for handling abrasive feeds asthe internal mixing introduces additional wearing of the equipment.Conventional two-fluid nozzles with internal gas/liquid mixing alsointroduce the risk of drying out and thereby clogging the mixingchamber.

Internal mixing nozzles give the possibility of an efficient liquid-gasreaction, but are limited in capacity by internal channelling andchannel dimensions. Internal parts in the nozzle, intended for improvingthe gas-liquid mixing, also disturb the flow, causing the span of thedroplet size distribution to rise. Internal parts in general complicatehandling, cleaning and causes wear. Furthermore viscous liquid feeds maybe difficult to process.

Examples of nozzles of the internal mixing type are well known in theart. U.S. Pat. No. 7,694,944 (GEA Niro) discloses a nozzle in which thegas is supplied in the axial direction of the nozzle. The nozzlecomprises a mixing chamber, one or more liquid inlets and at least onetangential gas inlet to the mixing chamber. In a commercially availableinternal mixing nozzle the atomising gas is supplied tangentially in aseparate pipe, which contributes to the radial dimensions of the nozzle.Furthermore, the mixing chamber of this prior nozzle comprises edges andobstructions resulting from structural conditions. Internationalpublished application WO 00/58014 discloses a sprayer in the form of anozzle having a tangential gas inlet to the mixing chamber and lateralliquid inlets. This nozzle suffers from insufficient mixing due to thegeometry of the nozzle.

Criterions for evaluating the performance of a two-fluid nozzle are: themean droplet size, the span of the droplet size distribution and notleast the specific gas consumption, meaning the amount of gas used toatomise a given amount of liquid, also called the gas-to-feed ratio. Inaddition to the criterions focused on the product quality, theproduction capacity of the two-fluid nozzle is also of highimportance—especially from a commercial point of view. Furthermore,increasing focus on clean technologies as well as increasing energyprices put forward additional requirements with respect to energyconsumption when operating and producing by spray processes.

The contact and mixing of gas and liquid is where external mixing TFNmeet their restrictions. External mixing TFN, where the gas mixes withthe liquid after leaving the nozzle typically through a ring-shapedaperture, meets the limitation when the gap in the gas exit becomes solarge that a larger part of the gas is lost into the surroundingatmosphere of the drying chamber, instead of reacting with the liquid.With external mixing TFN, the free expansion of the gas has thedisadvantage of being partly lost to the surrounding instead of addingenergy to break up the liquid. In the prior art this problem has beenattended.

Another type of nozzles utilizes pressurization of the liquid, meaningthat the feed concentrate is fed under pressure to the nozzle. Pressureenergy is converted to kinetic energy, and feed issued from the nozzleorifice as a high speed film that readily disintegrates into a spray asthe film is unstable. Sprays from pressure nozzles handling high feedrates are generally less homogeneous and coarser.

EP 408 801 B1 suggests a low pressurized liquid, internal mixingtwo-fluid nozzle which can function satisfactory even when low pressureis applied during a period of start-up as small droplets are produced.The spray nozzle unit is provided with a gas slit between the pressurenozzle and the air nozzle to give a part of the discharging air stream aswirling motion.

The present invention is directed to a high pressurized liquid externalmixing two-fluid nozzle that efficiently uses the atomizing gas. It iswell known within the art that the disadvantages of pneumatic nozzlesconcern the high cost of compressed air and low nozzle efficiency.Furthermore, a drawback with several of the pre-existing, conventionaltwo-fluid spray nozzle units is the limited capacity when very finedroplets are required. The object of the present invention is to providefor an external mixing pressurized two-fluid nozzle, which is energyefficient, provides high capacity while still producing fine droplets.

SUMMARY OF THE INVENTION

The present invention relates to an external mixing pressurizedtwo-fluid nozzle for atomising a liquid by means of a liquid pressureand a gas, comprising an inner feed liquid pipe extending axiallybetween an upstream end and a downstream end, having a feed liquidconduit, a feed liquid inlet positioned at the upstream end and a feedorifice positioned at the downstream end, and a co-axial first gas pipeextending radially outside the inner feed liquid pipe and forming afirst gas conduit between the first gas pipe and the inner feed liquidpipe, the first gas pipe having a gas outlet slit positioned at thedownstream end. The nozzle further comprises a co-axial second gas pipeextending radially outside the first gas pipe and forming a second gasconduit between the second gas pipe and the first gas pipe, the firstgas conduit being closed at the upstream end and the second gas conduitbeing closed at the downstream end, wherein the first gas conduit andthe second gas conduit are connected by one or more slot(s) beingadapted for providing a swirling motion of a gas flow.

Spray drying procedures with the external mixing two-fluid nozzleaccording to the above-mentioned design has proven to provide a highproduction capacity while still retaining a mean particle size and aspan wanted for. In prior art nozzles for external mixing the productionof fine particles in spray drying applications limit the capacity as theincreased liquid flow requires the gap in the gas exit to become largeror, alternatively the pressure to be increased. The effect is that alarger part of the gas is lost into the surrounding atmosphere, insteadof reacting with the liquid. However, with the external mixing two-fluidnozzle according to the invention the gas flow pattern at the outletslit is designed to require a reduced gas flow, thus ensuring increasedreaction with the liquid when the feed liquid is supplied with asubstantial pressure.

According to the present invention, the liquid is pre-atomized by anelevated liquid pressure to form a thin film, which is subsequentlyatomized into fine droplets by means of the pressurised gas. In priorart nozzles having a normal liquid pressure this pre-atomization doesnot form to the same extent. Typically, the formation of the droplets inprior art nozzles is mostly due to the high velocity of the gas, whichat high capacities is subject to limitations as presented in thebackground section i.a. incomplete atomisation leading to largerparticle sizes and broader distribution.

Surprisingly, the external mixing two-fluid nozzle of the presentinvention forms powders with a small span. The span expresses how widethe particle size distribution is. Aiming at a specific particle size, anarrow distribution is desired. A wide distribution of the droplet sizeis generally disadvantageous. The span, evaluated as (d90−d10)/d50 isnormally found in the range from 1 to 2 for the nozzle of the invention.

Within the two gas conduits of the nozzle, the swirl motion is generatedby directing the gas flow through one or more slots connecting the twogas conduits. The design and effectiveness of the atomisation mechanismsprovided by the pressurized two-fluid nozzle according to the inventionenables high-viscous liquid to be atomised at industrial applicable feedrates. In addition, the formation of a pre-atomisation of the liquidcombined with the full swirl motion of the gas enables the atomisationof the liquid feed at low gas flow rates.

It is a further advantage of the nozzle according to the invention thatthe high shear atomization takes place outside the nozzle itself as thenozzle will be well suited for handling abrasive feed liquids, and therisk of drying out and thereby clogging of the nozzle is avoided due tothe external contact between gas and liquid.

In a preferred aspect of the invention, the gas outlet slit and the feedorifice essentially are in the same horizontal position. The effect ofthis feature is that an external mixing is ensured, i.e. that the feedliquid and the atomization gas are mixed outside the sensitivecomponents of the nozzle. The inner feed liquid pipe may be retracted orprotruded relative to the tip of the first gas pipe to an inessentialdegree, such as +/−5 mm.

Usually, the inner feed liquid pipe, the first gas pipe and the secondgas pipe are concentric and tubular. The concentric and tubular designprovides for a uniform treatment of the atomization gas so that the flowpattern along the gas outlet slit is uniform. Furthermore, in preferredembodiments, the gas outlet slit is annular for a uniform gas dispersionto form, which provides for the formation of a cloud of droplets withina restricted volume of the drying chamber.

According to an aspect of the invention, the one or more slot(s)connecting the first gas conduit and the second gas conduit extendtangentially to the outer surface of the inner feed liquid pipe. Thisfeature adapts the one or more slots for providing a swirling motion ofthe gas once it flows from the second gas conduit through the one ormore slots and into the first gas conduit. In the event the nozzle holdsmore than one slot it is important that the slots extend tangentially tothe inner feed liquid pipe in the same direction, meaning that all slotsshould provide for the gas to flow in the same clockwise orcounter-clockwise direction around the inner feed liquid pipe, therebyenhancing the swirling motion of the gas.

The two-fluid nozzle according to the invention provides for the entiregas stream to flow through the one or more slots adapted for providing aswirling motion. The inventors found that compared to only providing forpart of the gas to flow through means for providing a swirling motion assuggested in EP 408 801 the design of the present invention imparts anincreased swirling motion. This in turn results in a lowered overall gasflow of the nozzle. However, due to the pre-atomising of the liquid bymeans of pressurising the liquid feed, the required amount ofatomisation gas is at a lower level. The swirling motion of the gas,however, provides for an improved atomisation of the liquid by impartingthe swirling/rotating motion to the liquid.

The one or more slots may be directed at an upwards or downwards anglerelative to the horizontal plane, such as +/−5° or more. The individualslots may be placed at different horizontal levels along the first gaspipe.

By providing a converging portion at the downstream end of the nozzle itmay improve both the mean droplet size distribution and the span of thedroplet size distribution. The converging may be at an angle of 5° to80° or more preferable of 10° to 45° relative to the vertical plane.

The two-fluid nozzle of the invention may be prepared in any suitablematerial. For highly abrasive feed liquids, however, it may beadvantageous that at least the inner feed liquid pipe wear parts are ofa wear resistant material, such as a ceramic material.

To adapt the nozzle of the invention to various process conditions andfeed liquids, the inner feed liquid pipe and/or the first gas pipe maybe exchangeable and/or adapted for receiving one or more inserts, and/orthe second gas pipe outer wall is adapted for mounting in a lance. Thedesign could be a nozzle lance with concentric pipes and a nozzle headas described herein mounted in the downstream end. Such nozzle head orparts hereof may be exchangeable to adapt to a relevant feed capacity.

The invention also relates to a spray processing method for producing aspray dried powder. The method includes the steps of: providing a spraydrying apparatus comprising an external mixing two-fluid nozzle havinginlets for feed liquid and atomization gas, a drying chamber having adrying gas inlet and exits for spent drying gas/atomising gas andproduced powder, spraying in the drying chamber the feed liquid throughthe external mixing two-fluid nozzle by means of liquid pressure and theatomisation gas into droplets, drying the droplets to a powder,discharging the powder trough the exit for produced powder and the spentgas through the exit for spent gas, wherein the atomisation gas issupplied to the nozzle with a pressure in the range of 0.2 to 10 bar(g),the entire amount of atomisation gas in the nozzle is provided with aswirling motion, the feed liquid is supplied to the nozzle with apressure at or above 8 bar(g), and the weight ratio of atomisation gasflow to feed liquid flow is in the range of 0.1 to 10.

The inventors surprisingly found that providing a pressurised liquidfeed to a two-fluid nozzle providing the atomizing gas with a swirlingmotion, results in a reduction in the required gas pressure even for theproduction of powders with a mean particle size below 50 μm. Incomparison to conventional two-fluid nozzles, the external mixingtwo-fluid nozzle according to the present invention has lower energyconsumption. This is presently believed to be because energy input foratomization provided by elevated liquid pressure is utilized moreefficiently compared to energy input provided by elevated air pressure.Conventional two-fluid nozzles apply pressurized gas for atomization,whereas the external mixing two-fluid nozzle according to the presentinvention applies a combination of pressurized liquid and pressurizedgas. Furthermore, the use of conventional two-fluid nozzles withexternal mixing will have a limited capacity when very fine droplets arerequired, whereas the two-fluid nozzle according to the presentinvention will have an increased liquid capacity, in some embodiments upto e.g. 500 kg/h.

The swirling motion may be provided by a number of means, includinginclining slats in the passageway of the atomising gas in the nozzle,meandering gas channels formed in the nozzle, etc. According to apreferred aspect of the invention the swirling motion is provided by oneor more slots, which connects a second gas conduit and a first gasconduit, said second conduit being connected to a gas supply and formedbetween a first gas pipe and a second gas pipe extending radiallyoutside the first gas pipe and said first gas conduit being formedbetween an inner feed liquid pipe and the first gas pipe, said secondgas conduit being closed at the downstream end, said first gas conduitbeing closed at the upstream end and connected to a gas outlet slit inthe downstream end. In a certain embodiment, the external mixingtwo-fluid nozzle used in the above method is a nozzle as disclosed inthe attached claims.

The slots in the nozzle are designed to give the atomization gas therequired swirl without imposing the gas flow to unnecessary friction. Ina certain embodiment, the one or more slot(s) connecting the first gasconduit and the second gas conduit extend tangentially to the outersurface of the inner feed liquid pipe. Due to the fact that the entireamount of gas is guided through the one or more slots a completeswirling motion of the gas is obtained. The swirling motion of the gasprovides for an improved atomisation of the liquid by imparting theswirling/rotating motion to the liquid.

The feed liquid is provided with a certain pressure before ejection intothe drying chamber. The pressure is usually not less than 5 bar(g) ifthe benefits of the invention is to be obtained. In a preferred aspectthe liquid is supplied to the nozzle with a pressure of 10-150 bar(g).In general, a highly viscous feed liquid requires a higher feed liquidpressure than a less viscous feed liquid.

The atomisation gas is supplied to the nozzle with a pressure of atleast 0.2 bar(g). The pressure is generally not above 10 bar(g) due toprocess economics. In a preferred aspect the atomising gas is suppliedwith a pressure of 0.5-5 bar(g) and more preferred with 1-2 bar(g).

To obtain a sufficient swirl of the atomisation gas it is ejected fromthe nozzle at a rotational speed of 30 m/s or more. Suitably, therotational speed does not exceed 500 m/s. In a preferred embodiment theatomising gas is ejected from the nozzle at a rotational speed in therange of 50 m/s to 400 m/s, typically 100-200 m/s.

The advantage of the present invention is that the combined pressuringof atomization gas and feed liquid is less energy consuming thanpredominate pressurizing of the atomization gas. According to theinvention, the weight ratio of atomizing gas flow to feed liquid flow isin the range of 0.1 to 10, suitably the weight ratio of atomisation gasflow to feed liquid flow is from 0.5 to 5 and more suitable from 1-3.

The method of the present invention can produce droplets in varioussizes and distributions. The invention shows most of its benefits whensmall droplets are produced. Therefore, in a preferred aspect the meansize of the droplets is less than 30 μm.

The present invention has the important feature of being able to produceparticles of a small size combined with a high liquid flow capacity. Ina certain embodiment of the invention, the liquid flow capacity of theexternal mixing two-fluid nozzle is 100 kg/h or above.

According to an aspect of the invention, two or more external mixingpressurized two-fluid nozzles are provided in the spray dryingapparatus. As the feed liquid flow through the nozzle is controlled atan elevated liquid pressure it will be possible to distribute liquidbetween multiple nozzles in an easy manner.

The powder produced by the method of the invention may be of variousmaterials. Usually, the spray dried powder is selected from the groupconsisting of powders for use in lithium ion batteries or othersecondary batteries, polymer powders, starch or gelatine powders, coffeepowder, powders from abrasive feeds, inorganic powders, hard metalpowders, pharmaceutical powders and congealed powders.

The method of the present invention is found to be suited for viscousliquids as enabling the processing of a feed with a higher dry mattercontent compared to processes using conventional nozzles. The method,furthermore, holds the advantages of external mixing, thus, making thespray processing method particularly suitable for spray drying productsfrom abrasive feeds.

The atomisation gas may be air, nitrogen, carbon dioxide, or any othersuitable gas.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view along the axis of the external mixingtwo-fluid nozzle in an embodiment of the present invention, and

FIG. 2 is a radial cross-sectional view of the external mixing two-fluidnozzle in an embodiment of the invention, in an axial position whereboth gas conduits and connecting slots are present.

FIG. 3 is a schematic view of a spray drying apparatus according to thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

In the following an embodiment of the present invention will bedescribed in details with reference to FIG. 1 and FIG. 2.

The external mixing two-fluid nozzle (17) is provided with an inner feedliquid pipe (1) extending axially between an upstream end and adownstream end of the nozzle. The inner feed liquid pipe (1) forms achannel, which provide for a feed liquid conduit (2). At the upstreamend of the inner feed liquid pipe is a feed liquid inlet (3) throughwhich the feed liquid can enter into the feed liquid conduit (2). At thedownstream end of the inner feed liquid pipe (1) is a feed orifice (4)through which the liquid feed can exit the liquid feed conduit (2).Surrounding the inner feed liquid pipe (1) is a first gas pipe (5). Thefirst gas pipe (5) extends co-axially with the inner feed liquid pipe(1) on the outside. The radius of the first gas pipe (5) is larger thanthe radius of the inner feed liquid pipe (1), and the first gas pipe (5)provides a pipe wall, which is spaced from the wall of the inner feedliquid pipe (1), thus providing a first gas conduit (6) between theinner feed liquid pipe (1) and the first gas pipe (5). The first gaspipe is provided with a gas outlet slit (7) at the downstream end of thenozzle. The first gas conduit does not extend all the way through thenozzle but is closed at the upstream end of the nozzle. Surrounding thefirst gas pipe (5) is a second gas pipe (8), which extends radiallyoutside the first gas pipe (5). Thereby, the radius of the second gaspipe (8) is larger than the radius of the first gas pipe (5). The wallsof the first and second gas pipes are spaced, thus providing a secondgas conduit (9) between the pipe walls of the first and second gas pipe.The second gas conduit (9) is open at the upstream end of the nozzle butclosed at the downstream end. The nozzle features one or more slots (10)provided in the first gas pipe (5). The one or more slots (10) gothrough the wall of the first gas pipe (5) thereby connecting the firstand second gas conduits. The one or more slots (10) are adapted forproviding a swirling motion of the gas flow.

During operation of the external mixing two-fluid nozzle a liquid feedstream typically enters the nozzle at the feed liquid inlet (3) andflows axially through the nozzle via the feed liquid conduit (2). Thus,the feed liquid flows downstream through the nozzle. The feed liquidstream exits the nozzle at the feed orifice (4). An atomisation gasinitially flows parallel to the feed liquid stream and in the samedownstream direction. The atomisation gas enters the nozzle at theupstream end into the second gas conduit (9) of the second gas pipe (8),which is open at the upstream end. From the second gas conduit (9) theatomisation gas flows into the first gas conduit (6) of the first gaspipe (5) through the the four slots (10). As the atomisation gas flowsthrough the one or more slots (10) it obtains a swirling motion.Maintaining the swirling motion the atomisation gas flows through thefirst gas conduit (6) and exits through the gas outlet slit (7).

In the present description subsequent claims the term bar(g) refers tothe pressure in bars above ambient or atmospheric pressure. When thepresent description and claims refers to spray processing or spraydrying, a variety of different spray methods and processing methods iscomprised in the term, including spray drying, spray congealing andspray granulation. It will be understood by a person skilled in the artthat when spray congealing is performed, the drying gas is substitutedwith a cooling gas.

The powders for use in lithium-ion batteries produced by the presentinvention may be any of the various lithium ion salt used forrechargeable batteries. By way of examples only, the powders produced bythe method of the present invention may be of the following materials:lithium cobalt oxide, lithium iron phosphate or another polyanion,LiNiO₂ or lithium manganese oxide or another spinel. Also othersecondary battery powders than powders for use in lithium-ion batteriesmay be produced by this method. The powder material may also be amixture of salts, such as LiCo_(1/3)Ni_(1/3)Mn_(1/3)O₂. The powders mayoptionally be doped with aluminium, niobium or zirconium.

A spray drying apparatus for implementing the present invention includesthe above external mixing pressurized two-fluid nozzle (17) having aninlet (11) for receiving a feed liquid and an inlet (12) for receivingatomization gas, a drying chamber (13) for receiving the feed liquid andthe atomization gas from the nozzle (17) and having a drying gas inlet(14) for receiving a drying gas, and an exits (15), (16) for dischargingspent gas, comprising spent drying gas and spent atomizing gas andproduced powder, respectively.

EXAMPLES Example 1

Spray Drying of Lithium Ion Battery Powder

A lithium ion battery powder was spray dried in a GEA Niro SD 6.3 pilotspray dryer using a conventional two-fluid nozzle with external mixingand the GEA Niro COMBI-NOZZLE™ according to the present invention withthe following results:

TABLE 1 Conventional two-fluid GEA Niro nozzle COMBI-NOZZLE ™ Liquidfeed rate kg/h 15 13 Air consumption kg/h 30 22 Air pressure bar(g) 3 2Feed pressure bar(g) 0.5 11 Air to liquid ratio kg/kg 1.8 1.7 Averageparticle size μm 14 7 Span of particle size n 2.1 1.8

Example 2

Spray Drying of e-PVC Latex

e-PVC latex is often spray dried to make fine powder particles andusually a large number of conventional two-fluid nozzles are requiredfor this purpose as the maximum capacity of these nozzles are around50-65 kg/h in order to make the required average particle size of around20 micron. By application of the nozzle according to the invention it ispossible to achieve a smaller average particle size with a significantlylower consumption of compressed air. Furthermore the liquid feedcapacity of one COMBI-NOZZLE™ can be 200 kg/h, 500 kg/h, or higher.

TABLE 2 Nozzle type Conventional two-fluid GEA Niro nozzleCOMBI-NOZZLE ™ Air to feed kg/kg 1 1.25 1.5 1 1.25 1.5 ratio Average μm38 33 28 33 23 17 particle size

Example 3

Atomization of High Viscosity Melts

A highly viscous melt of a polymer has been spray congealed using theCOMBI-NOZZLE™ at the below conditions. By conventional atomizationtechnique the melt could not be satisfactorily congealed due toformation of filaments caused by poor droplet formation.

TABLE 3 Melt feed rate kg/h 95 Liquid pressure bar(g) 100 Air to liquidratio kg/kg 1.4 Average particle size μm 21

Example 4

Control of Span of Droplet Size

The span of the droplet size distribution from the COMBI-NOZZLE™ hasbeen examined by spraying of water and the span has been influenced byvarying the theoretical spray angle of the liquid injection nozzle. Thefollowing results have been achieved using Malvern droplet sizemeasurement apparatus:

TABLE 4 Theoretical spray angle degree 50 65 80 Mean droplet size μm 1815 13 Span of droplet size n 0.95 1.1 1.2

1. An external mixing pressurized two-fluid nozzle for atomizing aliquid, in a spray drying apparatus, using a liquid pressure and anatomization gas, the external mixing pressurized two-fluid nozzlecomprising: an inner feed liquid pipe extending axially between anupstream end and a downstream end, the inner feed liquid pipecomprising: a feed liquid conduit; a feed liquid inlet positioned at theupstream end; and a feed orifice positioned at the downstream end; theexternal mixing pressurized two-fluid nozzle further comprising: anatomization gas inlet for receiving the atomization gas, and a co-axialfirst gas pipe extending radially outside the inner feed liquid pipe andforming a first gas conduit between the first gas pipe and the innerfeed liquid pipe, wherein the first gas pipe has a gas outlet slitpositioned at the downstream end, a co-axial second gas pipe extendingradially outside the first gas pipe and forming a second gas conduitbetween the second gas pipe and the first gas pipe, the second gasconduit being adapted to receive atomization gas from the atomizationgas inlet, wherein the first gas conduit is closed at the upstream endand the second gas conduit is closed at the downstream end, wherein thefirst gas conduit and the second gas conduit are connected by one ormore slot(s) adapted for providing a swirling motion of an atomizationgas flow, and wherein the second gas conduit extends parallel to thefeed liquid conduit for the atomization gas in the second gas conduit toflow parallel to, and in the same direction as, a feed liquid in thefeed liquid conduit.
 2. The external mixing pressurized two-fluid nozzleaccording to claim 1, wherein the gas outlet slit and the feed orificeare in essentially a same horizontal position.
 3. The external mixingpressurized two-fluid nozzle according to claim 1, wherein the innerfeed liquid pipe, the first gas pipe and the second gas pipe areconcentric and tubular.
 4. The external mixing pressurized two-fluidnozzle according to claim 1, wherein the gas outlet slit is annular. 5.The external mixing pressurized two-fluid nozzle according to claim 1,wherein the one or more slot(s) connecting the first gas conduit and thesecond gas conduit extend tangentially to an outer surface of the innerfeed liquid pipe.
 6. The external mixing pressurized two-fluid nozzleaccording to claim 1, wherein the one or more slots are directed ateither an upwards angle or a downwards angle relative to a horizontalplane.
 7. The external mixing pressurized two-fluid nozzle according toclaim 1, wherein the inner feed liquid pipe and the first gas pipeconverge radially towards a center at the downstream end.
 8. Theexternal mixing pressurized two-fluid nozzle according to claim 1,wherein wear parts of the inner feed liquid pipe are comprised of a wearresistant ceramic material.
 9. The external mixing pressurized two-fluidnozzle according to claim 1, wherein at least one of: the second gaspipe outer wall is adapted for mounting in a lance; and at least one ofthe inner feed liquid pipe and the first gas pipe are at least one ofexchangeable and adapted for receiving one or more inserts.
 10. A spraydrying apparatus comprising: an external mixing pressurized two-fluidnozzle for atomizing a liquid using a liquid pressure and an atomizationgas, the external mixing pressurized two-fluid nozzle comprising: aninner feed liquid pipe extending axially between an upstream end and adownstream end, the inner feed liquid pipe comprising: a feed liquidconduit; a feed liquid inlet positioned at the upstream end; and a feedorifice positioned at the downstream end; the external mixingpressurized two-fluid nozzle further comprising: an atomization gasinlet for receiving the atomization gas, and a co-axial first gas pipeextending radially outside the inner feed liquid pipe and forming afirst gas conduit between the first gas pipe and the inner feed liquidpipe, wherein the first gas pipe has a gas outlet slit positioned at thedownstream end, a co-axial second gas pipe extending radially outsidethe first gas pipe and forming a second gas conduit between the secondgas pipe and the first gas pipe, the second gas conduit being adapted toreceive atomization gas from the atomization gas inlet, wherein thefirst gas conduit is closed at the upstream end and the second gasconduit is closed at the downstream end, wherein the first gas conduitand the second gas conduit are connected by one or more slot(s) adaptedfor providing a swirling motion of an atomization gas flow, and whereinthe second gas conduit extends parallel to the feed liquid conduit forthe atomization gas in the second gas conduit to flow parallel to, andin the same direction as, a feed liquid in the feed liquid conduit. 11.The spray drying apparatus according to claim 10, wherein the gas outletslit and the feed orifice are in essentially a same horizontal position.12. The spray drying apparatus according to claim 10, wherein the innerfeed liquid pipe, the first gas pipe and the second gas pipe areconcentric and tubular.
 13. The spray drying apparatus according toclaim 10, wherein the gas outlet slit is annular.
 14. The spray dryingapparatus according to claim 10, wherein the one or more slot(s)connecting the first gas conduit and the second gas conduit extendtangentially to an outer surface of the inner feed liquid pipe.
 15. Thespray drying apparatus according to claim 10, wherein the one or moreslots are directed at either an upwards angle or a downwards anglerelative to a horizontal plane.
 16. The spray drying apparatus accordingto claim 10, wherein the inner feed liquid pipe and the first gas pipeconverge radially towards a center at the downstream end.
 17. The spraydrying apparatus according to claim 10, wherein wear parts of the innerfeed liquid pipe are comprised of a wear resistant ceramic material. 18.The spray drying apparatus according to claim 10, wherein at least oneof: the second gas pipe outer wall is adapted for mounting in a lance;and at least one of the inner feed liquid pipe and the first gas pipeare at least one of exchangeable and adapted for receiving one or moreinserts.
 19. A spray drying apparatus comprising: an external mixingpressurized two-fluid nozzle for atomizing a liquid using a liquidpressure and an atomization gas, the external mixing pressurizedtwo-fluid nozzle comprising: an inner feed liquid pipe extending axiallybetween an upstream end and a downstream end, the inner feed liquid pipecomprising: a feed liquid conduit; a feed liquid inlet positioned at theupstream end; and a feed orifice positioned at the downstream end; theexternal mixing pressurized two-fluid nozzle further comprising: anatomization gas inlet for receiving the atomization gas, and a co-axialfirst gas pipe extending radially outside the inner feed liquid pipe andforming a first gas conduit between the first gas pipe and the innerfeed liquid pipe, wherein the first gas pipe has a gas outlet slitpositioned at the downstream end, a co-axial second gas pipe extendingradially outside the first gas pipe and forming a second gas conduitbetween the second gas pipe and the first gas pipe, the second gasconduit being adapted to receive atomization gas from the atomizationgas inlet, wherein the first gas conduit is closed at the upstream endand the second gas conduit is closed at the downstream end, wherein thefirst gas conduit and the second gas conduit are connected by one ormore slot(s) adapted for providing a swirling motion of an atomizationgas flow, and wherein the second gas conduit extends parallel to thefeed liquid conduit for the atomization gas in the second gas conduit toflow parallel to, and in the same direction as, a feed liquid in thefeed liquid conduit, said spray drying apparatus further comprising adrying chamber for receiving the feed liquid and the atomization gasfrom the nozzle and having a drying gas inlet for receiving a dryinggas, and a first exit for discharging spent gas, comprising spent dryinggas and spent atomization gas, and a second exit for dischargingproduced powder.
 20. The spray drying apparatus according to claim 19,wherein the gas outlet slit and the feed orifice are in essentially asame horizontal position.
 21. The spray drying apparatus according toclaim 19, wherein the inner feed liquid pipe, the first gas pipe and thesecond gas pipe are concentric and tubular.
 22. The spray dryingapparatus according to claim 19, wherein the gas outlet slit is annular.23. The spray drying apparatus according to claim 19, wherein the one ormore slot(s) connecting the first gas conduit and the second gas conduitextend tangentially to an outer surface of the inner feed liquid pipe.24. The spray drying apparatus according to claim 19, wherein the one ormore slots are directed at either an upwards angle or a downwards anglerelative to a horizontal plane.
 25. The spray drying apparatus accordingto claim 19, wherein the inner feed liquid pipe and the first gas pipeconverge radially towards a center at the downstream end.
 26. The spraydrying apparatus according to claim 19, wherein wear parts of the innerfeed liquid pipe are comprised of a wear resistant ceramic material. 27.The spray drying apparatus according to claim 19, wherein at least oneof: the second gas pipe outer wall is adapted for mounting in a lance;and at least one of the inner feed liquid pipe and the first gas pipeare at least one of exchangeable and adapted for receiving one or moreinserts.